Tray-shaped packaging

ABSTRACT

The invention relates to a tray-shaped packaging for food comprising a bottom and a circumferential margin. The bottom comprises at least one collecting section and at least one supporting section, wherein the support section comprises a plurality of elevations for carrying a product, and wherein the collecting section at least in a certain area has a greater depth relative to the margin of packaging than the support section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims priority to European Application Number12004227.0 filed Jun. 1, 2012, to Patricia A. Chee and Ronald W. Nelsonentitled “Tray-Shaped Packaging,” currently pending, the entiredisclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a tray-shaped packaging, in particular for foodproducts, the packaging having a bottom and a circumferential margin.

BACKGROUND OF THE INVENTION

Such a packaging as well as a packaging machine and method formanufacturing same are known, for example, from DE 102010034021 A1 orthe related document US 2012/0036815 A1.

EP 0 535 451 A1 discloses a comparatively simple packaging in particularfor food with a high grease content, such as bacon strips. Thispackaging is produced by simply placing two transparent foils on top ofeach other. In order to allow the bacon to become crispy during amicrowave treatment, the packaging comprises a pad underneath the foodproduct, this pad having hydrophobic and grease-absorbing properties.This pad can be produced in a rather complicated manner, for example,from blown microfibers (BMF).

Another bacon packaging is known from EP 1 939 098 A1.

SUMMARY OF THE INVENTION

It is the object of the present invention to provide a packaging that iseasy to manufacture, and which offers superior properties regarding atreatment of food products, in particular greasy food products.

Due to having a tray-shaped configuration with a bottom and acircumferential margin, the packaging according to the present inventionhas a three-dimensional shape and is very stable. The bottom of thepackaging can comprise at least one collecting section and at least onesupport section. The support section may comprise a plurality ofelevations for jointly supporting or carrying a product, in particular afood product. Supporting the product on a plurality of elevationsinstead of supporting same with a planar surface offers the advantage ofestablishing a drainage effect, which allows grease dripping from theproduct during a heating of the product to be guided away from theproduct. This allows the product (which might, for example, be bacon,ham or sausages) to become crispier during the heating process.

Further, the packaging bottom can comprise a collecting section. Thiscollecting section could synonymously be termed “reservoir section” andhas the function of collecting excess grease or other fluids, which dripfrom the product during a heat treatment. In order to ensure that thegrease or fluid is guided away from the product, the collecting section,in total or at least in a certain area (i.e., at least in a sub-range ofits total area), may have a greater depth relative to the margin of thepackaging than the support section. Typically, it may be advantageous tomanufacture the collecting section without any elevations in order tomaximize the storage volume of the collecting section.

The support section can be arranged between at least two collectingsections. This allows excess grease to be guided away from the heatedproduct even more efficiently.

In another embodiment, a support section may even be circumscribedentirely (i.e., on all sides) from a collecting section.

The elevations may be pin-shaped, pyramid-shaped, rib-shaped,dome-shaped or other suitable shapes. It is also conceivable to haveelevations of different size and/or different shape on a singlepackaging.

In principle, the elevations may be arranged in any configuration on thepackaging, which enables them to carry or support a product. In oneembodiment, the elevations are arranged in the form of a matrix having nlines and m columns, with n and m being integers and ≧1, respectively.Preferably, n and m are each >3, such that there are at least 4 linesand at least 4 columns of elevations. This will ensure a generallyhomogeneous distribution of the weight of the product, therebypreventing an undesirable deformation of the product.

In one embodiment, each of the elevations comprises a peak, and thepeaks of all elevations of a common support section are arranged in acommon plane. Depending on the product and on the optimum way to presentthe product within the packaging, the common plane may be planar orcurved.

Drainage channels leading towards a single collecting section or towardsone (or several) of the plurality of collecting sections may be arrangedbetween the elevations. This will ensure an even faster and moreefficient guiding of the excess grease away from the product.

This efficiency may be increased even further by providing the drainagechannels with a downward slope directed towards the collecting section.

Alternatively, or additionally, it is conceivable that the supportsection of the bottom is convex on its side facing the interior of thepackaging. The convex shape refers to the (virtual) surface combiningthe valleys between the elevations. The convex shape of the surface willagain lead to an efficient drainage of the excess grease towards thecollecting section.

In order to be able to cook or grill the products while remaining withinthe packaging, it is advantageous if the packaging is heat resistant upto a temperature of 150° C., preferably up to a temperature of at least200° C. When contemplating a use of the packaging in a microwave oven,it is further advantageous if the packaging is essentially transparentto microwave radiation.

An example of a material that may be used for the bottom and the marginof the packaging is a polyethylene (PET) web or foil. This packagingmaterial may both offer the desired heat resistance, and an advantageoustransparency.

Preferred examples include the use of a bi-axially oriented polyethylene(PET) foil (boPET foil) for at least the bottom and the margin of thepackaging. Such a boPET foil, which is obtainable (e.g., under the tradename Mylar) is very heat resistant and is also stable at temperaturesbelow the freezing point, such that the goods packaged with thismaterial can also be frozen. Further, this material is transparent andhas a high resistance against punching and stretching.

The invention is also directed to a deep drawing station for producing atray-shaped packaging of the above-described type from a web-likematerial, such as boPET, this deep drawing station preferably comprisinga heating device, for example an electrical heating device, as well as aforming or deep drawing tool.

Further, the invention also relates to a deep drawing packaging machinethat is configured for manufacturing a tray-shaped packaging of theabove-described type.

Other and further objects of the invention, together with the featuresof novelty appurtenant thereto, will appear in the course of thefollowing description.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawing, which forms a part of the specification andis to be read in conjunction therewith in which like reference numeralsare used to indicate like or similar parts in the various views:

FIG. 1 is a schematic side view of a thermoforming packaging machine;

FIG. 2 is a perspective view of a first embodiment of a packagingaccording to the present invention;

FIG. 3 is a top view of the packaging of FIG. 2;

FIG. 4 is a lateral view of the packaging of FIG. 2;

FIG. 5 is a perspective view of a second embodiment of a packagingaccording to the present invention;

FIG. 6 is a top view of the packaging of FIG. 5;

FIG. 7 is a lateral view of the packaging of FIG. 5;

FIG. 8 is a sectional view of a third embodiment of a packagingaccording to the present invention; and

FIGS. 9 a to 9 d are different embodiments of the elevations used in thepackaging according to the present invention.

Identical components are designated by identical reference numeralsthroughout the figures.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawingfigures, in which like reference numerals refer to like partsthroughout. For purposes of clarity in illustrating the characteristicsof the present invention, proportional relationships of the elementshave not necessarily been maintained in the drawing figures.

The following detailed description of the invention references specificembodiments in which the invention can be practiced. The embodiments areintended to describe aspects of the invention in sufficient detail toenable those skilled in the art to practice the invention. Otherembodiments can be utilized and changes can be made without departingfrom the scope of the present invention. The present invention isdefined by the appended claims and the description is, therefore, not tobe taken in a limiting sense and shall not limit the scope ofequivalents to which such claims are entitled.

FIG. 1 shows, in a schematic side view, a thermoform packaging machine 1comprising a forming station 2, a sealing station 3, a cross cuttingstation 4 and a longitudinal cutting station 5, which are arranged on amachine frame 6 in a working direction R in this sequence. On the inputside, a supply roll 7 is provided on the machine frame 6, from which afirst web-shaped material 8, e.g. a boPET foil, is unwound. In the areaof the sealing station 3, a material storage unit 9 is provided, fromwhich a second web material 10 (e.g., a cover film such as a PET foil)is unwound. On the output side, a discharge device 13 in the form of atransport conveyor may be provided at the thermoform packaging machine1, with which finished, singulated packages 21 are transported away.Furthermore, the packaging machine 1 can comprise a feeding device,which is not shown, said feeding device gripping the first web-shapedmaterial 8 and transporting it cyclically in a main work cycle in theworking direction R. The feeding device can, for example, be realized bylaterally arranged transport chains

In the embodiment shown, the forming station 2 (or deep-drawing station)is realized as a thermoforming station in which package lower parts ortray-shaped packagings 14 are formed in the first web-shaped material 8by thermoforming (or deep-drawing). The forming station 2 comprises aheating element 2 a and a forming tool 2 b and can be configured suchthat in the direction perpendicular to the working direction R severaltray-shaped packagings 14 are formed side by side. In the workingdirection R behind the forming station 2, an infeed line 15 is provided,in which the package lower parts 14 formed in the first web-shapedmaterial 8 are filled with the product 16.

The sealing station 3 may be provided with a closable chamber 17 inwhich the atmosphere in the tray-shaped packagings 14 can besubstituted, prior to sealing, by an exchange gas or by an exchange gasmixture (e.g., by gas flushing).

The cross cutting unit 4 can be configured as a punch separating thefirst web-shaped material 8 and the second web material 10 in adirection transversely to the working direction R between neighbouringpackage lower parts 14. In so doing, the cross cutting unit 4 works suchthat the first web-shaped material 8 may not be cut across the wholewidth of the web, but instead may remain uncut in at least an edge areathereof. This allows controlled further transport by the feeding device.

In the embodiment shown, the longitudinal cutting unit 5 is configuredas a blade arrangement by means of which the first web-shaped material 8and the second web material 10 are cut between neighbouring tray-shapedpackagings 14 and at the lateral edge of the first web-shaped material8, so that, downstream of the longitudinal cutting unit 5, singulatedpackages 21 are obtained.

The packaging machine 1 can additionally be provided with a controller18. This controller 18 is used for controlling and monitoring theprocesses taking place in the packaging machine 1. A display device 19with operating controls 20 serves to make the sequences of process stepsin the packaging machine 1 visible to an operator and to influence themby the operator.

FIG. 2 shows a perspective view of a tray-shaped packaging 14 of thepresent invention. As shown, the packaging 14 comprises a generallyhorizontal bottom 21, a circumferential and again substantiallyhorizontal margin 22, as well as side walls 23, circumscribing thebottom 22 and interconnecting the bottom 21 with the margin 22. Thebottom 21, margin 22 and side walls 23 of the packaging 14 can be deepdrawn from a web material, such as PET, boPET or a multilayer webmaterial. For example, any material disclosed in U.S. Pat. No. 7,705,078B2 can be used, this document being hereby incorporated by referencewith respect to the material.

The bottom 21 of the packaging 14 can comprise a central support section24, as well as two lateral collecting or reservoir sections 25, i.e.,one to either side of the support section 24. A step 26 may be presentbetween the support section and each of the collecting sections 25, suchthat each of the collecting sections 25 has a greater depth relative tothe margin 22 than the support section 24.

Further, a plurality of pin-shaped elevations 27 may be arranged on thesupport section 24. In one embodiment, the elevations are arranged in amatrix of n=11 lines and m=12 columns The elevations 27 have a heightof, for example, 1-3 mm above the remainder of the support section 24.They serve to support the underside of a product, in particular, a foodproduct, such as bacon, ham or sausages placed on the support section24.

FIG. 3 shows a top view of the tray-shaped packaging 14 of FIG. 2. FIG.4 shows a lateral view of the packaging 14. From FIG. 4, it might beappreciated that the step 26 provides a smooth transition from thesupport section 24 towards the collecting sections 25, respectively. Itmight further be appreciated that the elevations 27 have a height thatis low enough in order to allow sufficient space for the product betweenthe peak of the elevations and a cover foil 28 sealed to the margin 22with a circumferential seal, the cover foil 28 extending in the sameplane as the margin 22.

FIG. 5 shows a second embodiment of a packaging 14 of the presentinvention. This second embodiment of a tray-shaped packaging 14 isconsistent with the first embodiment in comprising a central supportsection 24 and two lateral collection sections 25, as well as a margin22 and side walls 23 circumscribing the bottom 21.

In contrast to the first embodiment, however, the elevations 27 are nowpyramid-shaped. The pyramidal elevations 27 are arranged in a matrixpattern. Again, a step 26 is present between the central support section24 and each of the collecting sections 25, such that each collectingsection 25 entirely has a larger depth relative to the margin 22 thanthe support section 24.

FIG. 6 shows a top view of the tray-shaped packaging 14 of FIG. 5. FIG.7 shows a lateral view of the packaging 14 of FIG. 5. FIG. 7 allowsappreciating in particular the pyramid shape of the elevations 27.

In each of the embodiments of the packaging 14 according to FIG. 2 or 5,drainage channels 29 are provided between the elevations 27 (cf. FIGS. 3and 6). These drainage channels 29 are configured to lead excess greaseor liquid dripping from the product towards one of the collectingsections 25.

Further, FIGS. 4 and 7 show that the tray-shaped packaging 14 may reststably on the two collecting sections 25 when it is placed on ahorizontal surface, such as an oven tray. Due to the step 26, thecentral support section 24 is then elevated with respect to the surfaceon which the packaging 14 is placed, such that hot air can flow aroundthe complete packaging 14, in particular below the support section 24.This accelerates the heating of the product within the packaging 14.

FIG. 8 shows a third embodiment of a tray-shaped packaging 14 accordingto the present invention. This embodiment is similar to the embodimentshown in FIG. 5, except for lacking a step between the central supportsection 24 and the two lateral collection sections 25. Rather, thebottom of the support section 24 has a convex shape on its side facingthe interior of the packaging 14. The elevations 27 on the supportsection 24 are again pyramid-shaped. However, the size of the elevations27 is smaller in the center and larger in the periphery of the supportsection 24. This ensures that the peaks 30 of all elevations 27 arearranged in a common plane (P), which is represented by a dashed line.In the present embodiment, this plane is planar, but it couldalternatively be curved.

FIG. 8 shows that the packaging 14 rests on a support surface 31, suchas an oven tray.

FIGS. 9 a to 9 d show different embodiments of the elevations 27, whichcan be provided on the support section 24. In FIG. 9 a, the elevation 27is pin-shaped. Its top surface constitutes the peak 30 of the elevation27, i.e., the pin-shaped elevation 27 has a planar, two-dimensional peak30.

FIG. 9 b shows the pyramid-shaped elevation 27 used in the embodiment ofFIG. 5. Here, the peak 30 corresponds to the peak of the pyramid.

FIG. 9 c shows a dome-shaped elevation 27, which may have a circular orellipsoidal cross-section.

FIG. 9 d shows a rib-shaped elevation 27. In this embodiment, theelevation 27 has a linear peak 30, corresponding to the top edge of therib.

The packaging 14 of the present invention is advantageous in particularfor greasy food products, such as bacon, ham and sausages. When beingplaced in an oven or a microwave oven and heated, the excess grease maydrip from the product and enter into the drainage channels 29 betweenthe elevations 27. From here, the grease may flow into the collectingsections 25, thereby allowing the food product to be crispier afterheating.

Starting from the described embodiments, the invention may be carriedout in various alternative ways. For example, any shape, size andarrangement of the elevations 27 are conceivable. In particular, theshape of the elevations 27 is not limited to the embodiments shown in 9a to 9 d. For example, elevations 27 may also have a conical shape.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference toother features and sub combinations. This is contemplated by and iswithin the scope of the claims. Since many possible embodiments of theinvention may be made without departing from the scope thereof, it isalso to be understood that all matters herein set forth or shown in theaccompanying drawings are to be interpreted as illustrative and notlimiting.

The constructions and methods described above and illustrated in thedrawings are presented by way of example only and are not intended tolimit the concepts and principles of the present invention. Thus, therehas been shown and described several embodiments of a novel invention.As is evident from the foregoing description, certain aspects of thepresent invention are not limited by the particular details of theexamples illustrated herein, and it is therefore contemplated that othermodifications and applications, or equivalents thereof, will occur tothose skilled in the art. The terms “having” and “including” and similarterms as used in the foregoing specification are used in the sense of“optional” or “may include” and not as “required”. Many changes,modifications, variations and other uses and applications of the presentconstruction will, however, become apparent to those skilled in the artafter considering the specification and the accompanying drawings. Allsuch changes, modifications, variations and other uses and applicationswhich do not depart from the spirit and scope of the invention aredeemed to be covered by the invention which is limited only by theclaims which follow.

What is claimed is:
 1. Tray-shaped packaging for a product, thetray-shaped packaging comprising: a bottom having at least onecollecting section and at least one support section, wherein the atleast one support section includes a plurality of elevations forsupporting the product; and a circumferential margin; wherein the atleast one collecting section at least in certain areas has a depthrelative to the margin that is greater than a depth of the supportsection to the margin.
 2. Tray-shaped packaging according to claim 1,wherein the support section is arranged between at least two collectingsections.
 3. Tray-shaped packaging according to claim 1, wherein thesupport section is circumscribed entirely by a collecting section. 4.Tray-shaped packaging according to claim 1, wherein the elevations arepin-shaped, pyramid-shaped, rib-shaped or dome-shaped.
 5. Tray-shapedpackaging according to claim 1, wherein the elevations are arranged inthe form of a matrix with n lines and m columns, wherein n and m areintegers and each larger than 1, preferably n and m≧4, respectively. 6.Tray-shaped packaging according to claim 1, wherein each elevationcomprises a peak and wherein the peaks of all elevations of each supportsection are arranged in a common plane.
 7. Tray-shaped packagingaccording to claim 1, wherein drainage channels leading towards the atleast one collecting section are provided between the elevations. 8.Tray-shaped packaging according to claim 7, wherein the drainagechannels have a downward slope towards the collecting section. 9.Tray-shaped packaging according to claim 1, wherein the support sectionof the bottom is convex on its side facing the interior of thepackaging.
 10. Tray-shaped packaging according to claim 1, wherein astep is arranged between the support section and the collecting section.11. Tray-shaped packaging according to claim 1, wherein the packaging isheat resistant up to a temperature of at least 150° C.
 12. Tray-shapedpackaging according claim 1, wherein the bottom and the margin of thepackaging are made from a PET foil.
 13. Tray-shaped packaging accordingto claim 1, wherein the bottom and the margin of the packaging are madefrom a bi-axially oriented PET foil.
 14. Deep drawing station forproducing a tray-shaped packaging, said deep drawing station comprisinga forming tool adapted for deep drawing a tray-shaped packaging with abottom and a circumferential margin, such that the bottom comprises atleast one collecting section and at least one support section, whereinthe support section comprises a plurality of elevations for supporting aproduct and wherein the collecting section at least partially has adepth relative to the margin of the packaging that is greater than adepth of the support section relative to the margin.